Miller CS-3 Owners manual

Page 1
February
1980
MODEL
CS-3
FORM:
OM-1086
OWN
ERS
MANUAL
MILLER
718
APPLETON
ADDITIONAL
ELECTRIC
BOUNDS
NWSA
PRINTED
WI
COPY
CODE
ST.
IN
P.O.
54912
PRICE
NO.
U.S.A.
4579
Box
USA
25
MFG.
1079
CENTS
HilliER
CO.
Page 2
j
(
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4~1
LIMITED
Miller
hereof,
its
Distributor/Dealer
to
furnished
materialasof
ranty
cessories
engines,
the
engines
date
to
year,
MILLERMATIC
wire
not
ranted
within
ment
provided
of
is
warranties
are
of
original
Except
components
such
including
result
Miller
shall
Equipment
the
the
to
Arc
2.
Original
All
3. All
4.
5.
Replacement
6.
Batteries
date
the
by
made
trade
as
from
following
welders,
welding
other
that
WARRANTY-Subject
Electric
Mfg.
time
Miller
their
that
and
with
items
respective
their
by
Millerisfree
the
by
other
or
accessories
of
warranted
purchase,
having
spot
parts
nozzles
defect
be
required
in
welder
the
below,
normal
that and
in
workmanship
event
specified
as
periods
user:
original
sources
power
main
power
(labor
and
guns
Millermatic
or
repair
is
notified
Miller
failure.
of
such
LIMITED
This
warranty
with
clusive
the
to
terms
Co.,
Appleton,
all
new
from
defect
of
place
respect
manufactured
and
other
manufacturer
Millers
useful
tips,
relay
in
come
nozzle
insulators
honor
to
of
failure
from
the
rectifiers
-
1
year
feeder/guns
Feeders
parts,
writing
Wisconsin
and
delivery
to
items
manufacturers,
warranty
life
of
and
contact
material.
or
warranty
resulting
date
of
and
components
only)
exclusiveoflabor.60
within
EFFECTIVE:
supersedes
other
no
and
unused
all
guarantees
conditions
warrants
Equipment
workmanship
Miller.
others.
sold
one
does
than
claims
from
No
trade
subject
if
any
year
not
the
welding
failure
on
a
Such
from
apply
nile
points,
does
defect
by
engines,
by
are
for
less
contactor
with
where
deliveryofEquip-
1
.
.
year
3
years
90
days
1
days
6
months
130)
thirty
days
WARRANTY
1,
MILLER
warranties
As
submitted
In
with
therefore
where
or,
the
reasonable
Miller
price
return
of
notice
mant
ANY
ANY
lION BREACH MIGHT
CUSTOM
ANY
FITNESS
ANY
CLUDED
EXCEPT
WRITING,
ULTIMATE
USERS EXPERIENCED
WELDING CONSUMER
TO,
MILLERS
1979
matter
a
the
respect
service
(less
of
on
EXPRESS
IMPLIED
AS
IMPLIED
AND
AND
AND
previous
d
war-
ac-
to
All
.
Ill
war-
year
JUNE
or
warranties
expressed
of
the
by
of
case
the
to
shall
be,
authorized
cost
station
reasonable
the
goods
of
apparent
the
warranty
WARRANTY,
TO
OF
CONTRACT
ARISE
OF
TRADE
WARRANTY
FOR
PARTICULAR
ALL
AND
DISCLAIMED
AS
MILLER
PURCHASE
FOR
EQUIPMENT
USE.
NO
WARRANTIES
L1P ~_~
and
is
or
implied.
policy
general
user
original
breach
Millers
quality
Millers
at
in
of
or
of
writing
repair
(4)
payment
depreciation
Customers
at
defect
claim
WARRANTY
PERFORMANCE,
WHICH,
BY
IMPLICATION,
COURSE
OR
EQUIPMENT
EXPRESSLY
PRODUCTS
OPERATION
IN
THE
AND
MILLER
RESELLER
TO,
L~P
ex
Miller
only,
within
the
of
warranty
goods,
any
(1)
option
or
failure,
procedures
Miller
by
or
replacement
oforcredit
based
risk
and Miller
NOT
repair
in
to
PROVIDED
GUARANTY
AND
FOR
BUT
OPERATION
OF
OF
DEALING,
MERCHANTABILITY
PURPOSE,
FURNISHED
BY
MILLER.
PROVIDED
ARE
COMMERCIAL/INDUSTRIAL
BY
BY
PERSONS
USE
AND
NOT
IS
ANY
FOR
AUTHORIZED
CONSUMER.
WARRANTIES
honor
may
foregoing
or
any
the
exclusive
(2)
or
appropriate
at
an
for
the
actual
upon
expense.
instruct
shall
followed.
be
HEREIN
REPRESENTA
OR
REMEDY
ANY
THIS
PROVISION,
RESPECT
WITH
MILLER
BY
BY
INTENDED
TRAINED
MAINTENANCE
CONSUMERS
DO
NOT
TO
L&P
claims
periods.
other
duty
remedies
replacement
(3)
cases,
authorized
purchase
use)
upon
Upon
receipt
the
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AND
FOR
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LAW,
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MILLER
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Page 3
ERRATA
SHEET
After
this
manual.
this
AMENDMENT
Amend
Spot
manual
Figure
Time
was
printed,
TO
SECTION
2-1.
InstallationOfControl
refinements
-
2
INSTALLATION
in
equipment
Effective
Unit
design
With
&
occurred.
No.
Style
OPERATION
This
JA
sheet
19
lists
exceptions
F
data
~
appearing
RETUR~T~O~
~
~ULDEp~
later
in
Item
Pg
Pg
23
24
14
Time
Range
Burnbeck
Or
Dia.
No
Mkgs
4
5
9
RC1
RC2
2
Time
Spot-Continuous
Part
No.
476
010
156
605
156
605
726
048
283
048
534
079 048 282
535
079
Control
Replaced
With
010 476
571
604
571
604
483
045
283
048 079
535
Deleted Deleted
045
493
328
080
534
079 079531
571
604
Switch
2-1.
Figure
BUSHING
InstallationOfControl
(qtychg)
CORD,portableNo.
CORD,
CASE RECEPTACLEW/PINS
.
CORD,
.
.
portable
SECTION
TERMALE,
trigger
RECEPTACLE
TERMINAL,
.
.CLAMP,cable29/64
CORD,
.
portable
184C(orderbyft)
No.
184C
1
male
pin
(consisting
W/SOCKETS,
female
1
No.
184C(orderbyft)
Unit
Description
(order
byft)
(description
of)
socket
free
chg)
hanging
(consisting
of)
TB-047
181-A
Quantity
5
3
ft
4
ft
1
1
4
1
1
4
1
3
ft
BE
SURE
TO
PROVIDE
MODEL
AND
SERIAL
NUMBERS
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1086
Page
A
Page 4
Page 5
1-1.
especially design,
GENERAL
for
use
installation,
troubleshooting
presented
to
assure
-
1 this the
have
damage
the
by lading
request
When ment,
(or
Style)
-
1
add
to
SWINGARC
trol/feeders.
tion
without between
control
the
2-1.
CAUTION
___________
control/feeder
pletely
piles.
IMPORTANT:
trol/feeder,
welding.
dual
1.
herein
optimum
2.
RECEIVING-HANDLING
equipment,
unit
and
occurred
that
clean
carefully
during
may
purchaser
and
freight
if
occasion
requesting
it
essential
is
Number
3.
DESCRIPTION
welding
spot
DIGITAL
When
of
either
continuous
the
to
welding
gun.
having
unit,
SPOT-CONTINUOUS
INSTALLATION
Prior
and
disconnected
only
Make
all
control/feeder.
Loosen
unit
ing
on
the
the
top
screws.
-
This
manual
in
familiarizing
operation,
of
this
should
equipment.
be
given
performance
all
packing inspect shipment.
have
occurredintransit
the
with
bill
to
carrier.
willbefurnished
file
claim
information
Model
that
the
of
equipment
-
This
and
burnback
-1
and
installed,
or
change
Mode
any
power
change
switch.
SECTION
(Figure
to
installing
we/ding
If
this
the connections
screws
of
from
the
unit
Left
control
power their
gun
6
SECTION
has
been
personnel maintenance,
All
careful
this
for
of
any
Any
-
Prior
material
damage
claims
A
copy
equipment.
by
arises.
concerning
Description
be
supplied.
control
Unit
capability
and
50
will
welding
this
-2,
unit
spot
interconnecting
source,
control/feeder,
is
accomplished
When
2-
2-1)
the
unit,
source
ensure
respective
is
used
withadual
be
left
the
secure
used
control.
top
can
the
to
of
and
1
prepared
with
and
information
consideration
to
installing
from
around
that
may
loss
for
be
bill
the carrier
this
equip
Serial
and
designed
to
selec
filed
the
con
must
of
the
iS
series
provide
capability
wiring
the
in
CON-
INSTALLATION
that
both
are
portion
power
for
by
com
sup-
con
spot
of
this
Set
tighten
4
-
INTRODUCTION
TINUOUS
the
are
control
capability position,
spot
1
operation,
power
of
on
read
to
The
TANT,
manual:
____________
operating,
be
hazard
______________
operating,
be
damage
t~iIi~
via
the
the
3
will
most
shunted
through
welding
-
4.
SAFETY
source
completely.
misuse
following
and
CAUTION
found
to
IMPORTANT
found
to
Under
be
found
efficient
b
OPERATION
2.
Connect
trol/feeder
PLG3.
3.
Connect unittothe
control/feeder.
4.
Connect
the
to
control/feeder.
5.
Connect unit
rear
6.
Connect
(supplied
7.
Connect
position,
of.the
out
the
through
the
the
control
capability.
-
Before
the
safety
or
welding
This
or
improper
definitions
NOTE
Under
and
maintenance
if
that
not
personnel.
Under
maintenance
and
if
that
not
equipment.
this
that
need
operation
the
6
gas
the
6
6
pole
the
4
TRIGGER
the
4
the
to
of
115
the
control/feeder.
115
the with
the
gun
the
control
circuit
unit
thereby
control/feeder
control
unit
sectionatthe
unit.
provides
the
equipment
generator
will
welding
blocks
help
apply
this
avoid
applications.
to
found
heading,
procedures
this
followed
heading,
carefully
procedures
carefully
heading,
special
of
prong
valve
prong
followed
explanato,y
emphasis
the
equipment.
male
into
the
male
plug
receptacle
male
pin
plug
receptacle
female
pole
Volt/Contactor
VoIt/Contactor
control/feeder)
the
to
plug
TRIGGER
weld
spot
functions
providing
burnback
and
in
When
the
electronically
is
put
of
front
CAUTION,
the
manual
possible
welding
should
injury
IMPOR
throughout
installation,
or
practices
create
may
installation,
or
practices
result
may
statements
obtain
to
from
plug
6
pole
PLG4
PLG2
the
on
PLG1
receptacle
to
receptacle
female
the
from
front
Control
rear
the
from
of
this
of
from
on
receptacle.
weld
SPOT
timed
into
be
due
this
will
a
will
in
the
con
plug
this
the
unit
the
this
the
cable
RC1.
Trigger
Receptacle4
Time
Spot
Control
Time
Range
Switch
Burnback
Time
Figure
2-1.
Control
Installation
Spot-Continuous
Of
Control
Switch
Unit
TB-047
~
the
DDSC
nected
DDSC
receptacle
to
control
receptacle
-
2
2.
SPOT-CONTINUOUS
-
When
2-1)
SPOT
position,
operation.
functionsofthe
weld
181
spot
The
control/feeder
as
time,
set
If
control,
DDSC
the
that
the
control/feeder
this
the
SPOT-CONTINUOUS
the
When
in
the
on
this
the
control
normally
unit.
control
the
operates
control
is
unit
trigger
gun
provides
CONTINUOUS
control
normally
unit,
used/n
and
goes
must
SWITCH
unit
is
conjunction
must
plug
the
plug
the
to
the
go
switchisin
timed
a
position,
not
are
and
available.
be
from
TRIGGER TRIGGER
(Figure
welding
available.
burnback
a
OM-1086
with
con
the
the
the
Page
1
Page 6
-
2
3.
TIME
TIME
RANGE
ranges.
vides
a
switchinthe
5
seconds.
to
-
2
SPOT desired
4.
SPOT
TIME
spot
Rotating
the
spot
This
control
be
misconstrued
-
2
2-1)
BURNBACK
5.
-
The
1.
Ensure
as
2.
Turn
3.
Place
desired
4.Ifin
BACK
If
5.
RANGE
Placing
time
range
lower
TIME
control
weld
SPOT
the
time.
weld
calibrated
is
BURNBACK
that
instructedinSection
all
on
the
position.
the
CONTINUOUS
time
in
SPOT
the
following
6.
Position
desired.
CAUTION:
_______
ternal
nected.
circuit,y
spection
Hazardous
Disconnect
work
or
Troubleshooting
ed
by
qualified
The
following
remedies this
unit.
Itisassumed
cording
has
been
to
personnel
chart
for
some
that
Section
functioning
developed.
SWITCH
switch
the
provides
switchinthe
of
.2
to
position
CONTROL
provides
within
time
TIME
control
in
actual
as
an
TIME
time
position
RANGE
voltages
unit
power
internal
is
designed
the
installation
2
of
this
properly
connections
and
the
circuitry
only.
troubles
proper
associated
SPOT-CONTINUOUS
control
steps.
TIME
of
this
of
of
proper
(Figure
two
upper
2.5
seconds.
provides
a
(Figure
the
capability
the
range
clockwise
percentage
time
setting.
CONTROL
control
SECTION
2.
equipment.
position,
proceed
proceed
switch
SECTION
are
as
before
manual,
as
long
attempting
inside
should
to
diagnose
that
has
until
spot
position
time
to
selected.
and
is
provided
have
switch
set
normal.
as
outlined
as
to
present
power
of
be
and
may
been
that
and
this
2-1)
weld
Placing
range
2-1)
select
increases
should
(Figure
to
3-
SEQUENCE
been
in
the
BURN-
time
range
4-
the
on
is
any
the
perform
provide
develop
made,
the
trouble
-
of
-
The
time
pro
the
2.5
The
vent
after
providing
of
trically
Rotating
creases
the
This
be
the
If
not
pro-
made
the
BACK
the
If
the ed.
7.
8.
CAUTION
___________
per
eye
Failure
bodily
9.
in
the
I~IIIl~
the
tionofthe
during
TROUBLESHOOTING
in
con
in
unit.
in
ac
unit
Use
while
trouble
cedures,
tion
malfunction,
should
IMPORTANT
control/feeder
switches
plication
the
electrode
the
weld
an
.25
seconds)
hot
after
the
the
burnback
control
misconstrued
electrode
time
control
electrode
BURNBACK
OF
OPERATION
Adjust
Set
BURNBACK
protective
protection
to
comply
damage.
Position
Once
switch
gun
spot
the
weld
this
chart
performing
is
not
the
should
be
strictly
are
before
be
in
wire
from
is
complete.
adjustable
that
the
time
the
wire
BURNBACK
time.
is
calibrated
actual
an
wire
stickstothe
setting
wire
burns
time
control
SPOT
TIME
time
Prior
to
we/ding,
clothing (glasses
gun
the
must
weld
cycle
in
(welding
and
result
may
and
commence
SPOT
not
cycle.
the
conjunction
troubleshooting
remedied
nearest
the
Factory
contacted.
manufacturers
followed.
Ensure
and
control
the
proper
proceeding
sticking
The
period
electrode
has
stopped
time
in
percentage
time
should
back
setting
control.
control.
it
welding
in
TIME
re/eased
be
If
the
cycle
with
after
Authorized
all
In
all
that
unit
position
with
the
to
control
(up
wire
workpiece
prevents
to
maximum
a
remains
this
feeding.
control
clockwise
and
should
setting.
the
contact
be
decreas
that
gloves)
be
put
permanent
to
the
comple
is
opened
diagram
BURN-
workpiece,
be
increased.
into
the
should
is
imperative
coat
and
helmet)
serious
spot
welding.
control
will
gun
not
the
begins
until
switch
finish.
circuit
procedures.
of
the
Service
and
welding
these
equipment
at
that
performing
cases
recommendations
connections
are
secure
for
troubleshooting.
elec
not
tube,
pro
and
on.
time,
If
the
pro
Sta
the
all
ap
by
in
Page
2
Page 7
TROUBLE
Gas
operate.
Control/feeder
not
Electrode.
electrically
valve
Wire CONTINUOUS
SPOT.
(and
feed
operates.
FROM
TRIGGERS
water)
wire.
wire
feeds
hot.
valve
energizes
feeds
Gas
(and
when
positon
2
I
3
but
but
will
but
not
will
is
not
water)
not
in
PROBABLE
not
Plug(s)
Switch
Control
lead
loose
plug.
from
Plug
contactor
loose
or
receptacle.
Component
circuit
board
SPOT-CONT
improperly
secure
the
welding
control
lead(s)
defective
I
wired.
I-----
CAUSE
receptacle(s).
loose
plug
switch
power
receptacle
the
unit.
control
NUOUS
or
control
source
loose
plug
printed
switch
-
REMEDY
Ensure
that
Secure
a
or
-
switch
Secure
loose
Secure
pluginreceptacle
source.
the
Ensure
their
respective
Replace
Check
wiring
printed
plugs
control
lead
leads
of
are
inside
terminals.
circuit
switch.
secure
plug
switch
board.
control
at
of
receptacle
control
receptacle(s).
receptacle
on
plug.
unit
and
control
and
plug
unit.
welding
secured
are
power
to
To
GAS/WATER
RECEPTACLE
GAS/WATER
To
FEEDER
VALVES
______J
4~
324445501
3
SOURCE
Circuit
2
0
0
o
Diagram
0
DEF
FEEDER
TO
5-
TO
a:
3>
8LK
PLG3
TO
1
I15VAC/CONTACTOF1
Figure
POWER
4-1.
00iT
EXIT
P.C.
S0ARD
FROM
Circuit
Diagram
No.
B-048
835-B
OM-1086
Page3
Page 8
Page 9
February
1980
MODEL
CS-3
FORM:
OM-1086
PARTS
LIST
Page 10
I
t
N
(0
.9
eq
U.
U,
I-
N
I-
OM-1086
Page
C)
(4
TC.047
Figure
i
~
Main
Assembly
182
Page 11
Item
No.
Dia.
Mkqs.
Factory
Part
No.
Description
Quantity
10
11 12 13
14
15
16
17
18
19
20
21 22 23
24
173
907
738
476
156
284
534
878 535
156
265
842
726 772 725
148
388
848 611
283
534
282 535
WRAPPER
CIRCUIT
TUBING,
CARD
steel
BUSHING,
CORD,
portable
CLAMP,cable
HOUSING
TERMINAL,
.
HOUSING
TERMINAL,
.
CORD,
portable
CONNECTOR,
CONNECTOR,
CABLE.
CABLE.
CASE
BLOCK,
power power
SECTION,
terminal
BRACKET,
SOCKET,
RELAY,
SPRING,
SWITCH,
KNOB,
NAMEPLATE
relay
24
hoiddown
toggle
pointer
RECEPTACLE,
TERMINAL,
.
RECEPTACLE,
TERMINAL,
.
ASSEMBLY,
OD
5/16
relief
strain
18
No.
PLUG
SOCKETS
&
female1socket
male
male
No.
PINS
&
1
18
6
PLUG
female 5C
3-20/2-18
5C
3-20/2-18
front/bottom/back
20
amp
mounting
11
pin
volts
3PDT
ac
-
DPDT
(order
4
pin
female
4
socket
1
male
17
x
5/8
x
4C
(orderbyft.)
(consisting
pin
4C
(orderbyft.)
contact
6
socket
6
pole
-
relay
relay
15
amp
model
by
flanged
socket
1
flanged
pin
timer
spot
ga
.570
(consisting
of)
10
amp
w/cable
(order
by
(order
by
125
volts
and
serial
size
11
(consisting
11
size
(See
Fig.
of)
clamps ft.) ft.)
numbers)
of)
(consisting
B
of)
Page
3)
....
049
2 3 4
5
6
7
048
081
010
605
079531
048 079
8
079
079
9
605 056 048 052 246
052 246 048
iT
038
048
080
CR53
S51
080
048 011
024 366
RC
RC2
048
1
079
048 079
1
1
4 4
3
ft.
2
1
4
1
.
4
4
ft.
1 1
3
ft.
2
ft.
1 1 1 1 1 1 1
2
1
1
4
1
4
F
actory
Part
No.
604 804
070
602
602
143
072
602
850
604
602
198
859
601
SURE
BE
SCREW,
SCREW, SCREW, SCREW,
SCREW, WASHER,
NUT,
PROVIDE
TO
sheet
machine
self
machine machine
steel
lock
-
hex
-
MODEL
Description
metal
-
steel
tapping
-
steel
.
steel
-
steel
6-32
-
hex
round
split
AND
washer
truss
truss
round
No.
hd
hd
hd
hd
6
SERIAL
hd
6-32
6-32
6-32
6-32
Attaching
8
No.
x
3/8
x
3/8
x
5/8
x
3/4
x
NUMBERS
3/8
Hardware
WHEN
ORDERING
REPLACEMENT
PARTS.
OM-1
086
Page
2
Page 12
Dia.
Mkgs.
Factory
Part
No.
Description
Quantity
048
B
Figure
C51,56
C52,53
C54 C54
C55
CR51
CR52
051,54
D55
Q51,52 053,54
R51 030 055
R52,54,65
R53
R55,57
R56 R58 R59 R60
R61,64
R62 R63
R66
R67,68
R69
S52
907
031
633
031
643
032
943
820
032
032
943
048
906
032945
032
946 202
026
037
243 022 037 289
030 024 030 630 030
937 030 709
030
004 030
738
.030
145
025
030
030
131
030 853
024
030 030
025 032 819
011
770
Circuit
Card
Assembly,
S~,ot
Timer
CAPACITOR,electrolytic80uf25voltsdc
uf
12
0.01
4.7uf35
4.7
volts
2.2
ac
uf
3PFT
CAPACITOR,
CAPACITOR, CAPACITOR, CAPACITOR,
RELAY,
enclosed
ceramic
tantalum
electrolylic
tantalum
RELAY,24voltsdcDPDT
SOCKET,
DIODE,
DIODE,
135
THYRISTOR,4amp200volts
TRANSISTOR,
RESISTOR, RESISTOR, RESISTOR,
RESISTOR,
RESISTOR,
RESISTOR,
POTENTIOMETER, POTENTIOMETER,
RESISTOR,
POTENTIOMETER,
RESISTOR, RESISTOR,
RESISTOR,
RESISTOR,
SWITCH,
relay
1
ampere
zener
toggle
400
18
volts
unijunction
carbon carbon
WW
fixed
carbon
carbon
carbon
carbon
carbon
carbon
carbon
carbon
SPDT
2
watt
0.5
0.5
1
watt
0.5
carbon
carbon
0.5
carbon
0.5
0.5
0.5
0.5
5
volts
I
watt
watt
11
watt
watt
watt
watt
watt watt
watt
amp
straight
5OMA
10
1000
watt
10
150
10K
1
1
100
1
2200
1000
100
390K
125
(See
500
volts
volts
35
uf
volts
35
volts
polarity
35
volts
ohm
ohm
100
ohm
ohm
ohm
ohm
turn2watt
0.25
turn
ohm
2
turn
watt
ohm ohm
ohm
ohm
volts
Fig.APage
dc
dc
dc
dc
500K
2000
watt
ohm
50K
ohm
ohm
Item
2
2)
2 2
1 1 1 1 1
2
4
1
2
2
1
3
1
2
1 1
1 1
2
1 1 1
2
1 1
Page
BE
COMPONENTS
QUALIFIED
B
Figure
AND
SURE
TO
PROVIDE
3
MODEL
SERIAL
NUMBERS
Circuit
Card
WHEN
Assembly,
ORDERING
TO
PERSONNEL
Timer
S,iot
REPLACEMENT
BE
REPLACED
ONLY.
PARTS.
BY
TA-047
180
Page 13
Page 14
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